Senior Propulsion Engineer (Rocket Motors)

Castelion Corporation•Rio Rancho, NM

About The Position

We are seeking a Senior Propulsion Engineer to design, build, and test rocket motor systems for Castelion's long-range hypersonic strike vehicles. This role is critical to delivering reliable, high-performance propulsion across all mission phases. You will work hands-on with multidisciplinary engineering teams to develop solid rocket motors and associated hardware from concept through flight test in a fast-paced, hardware-driven environment.

Requirements

Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field
5+ years of experience in rocket propulsion design, analysis, and testing for aerospace or defense applications
Strong background in solid rocket motor design, including internal ballistics, grain design, and nozzle performance
Experience with propulsion testing, including static fire test setup, instrumentation, and data analysis
Familiarity with structural and thermal design considerations for high-temperature, high-pressure systems
Proficiency in analysis and modeling tools (e.g., MATLAB, ANSYS, or equivalent)
Experience with hardware build, integration, and troubleshooting in a lab or test environment
Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high test cadence environment
U.S. citizenship is required

Nice To Haves

While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required.

Responsibilities

Design and develop rocket motor systems, including grain geometry, case structures, insulation, and nozzle assemblies
Lead the architecture and detailed design of propulsion hardware to meet performance, structural, and thermal requirements
Perform internal ballistics, thermal, and structural analyses to ensure motor performance and reliability under extreme operating conditions
Work closely with structures, thermal, GNC, and manufacturing teams to ensure seamless integration of propulsion systems with the vehicle
Support propellant selection, processing, and characterization in collaboration with materials and manufacturing teams
Plan and execute static fire tests and development test campaigns, including instrumentation, data collection, and post-test analysis
Conduct failure analysis and root cause investigations, driving design improvements and risk reduction
Define and execute qualification and flight test plans, translating results into system-level improvements
Optimize designs for performance, mass, manufacturability, and operational reliability
Mentor junior engineers and contribute to best practices in propulsion system design and testing
Partner closely with program leadership to make technical trades aligned with mission success

Benefits

Meaningful long-term equity
Four (4) weeks of paid time off
Ten (10) company-paid holidays
Comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage
Dental and vision plans
Paid parental leave
$100 monthly fitness stipend
Onsite EV charging
Catered meals
Company-covered food during high-demand periods
Fully stocked kitchen